Process of making curved roofing elements and product thereof



-April 15, 1930.

L. KIRSCHBRAUN 1,754,771 PROCESS OF MAKING CURVED ROOFING ELEMENTS AND PRODUCTIHEREOE 7 Original Filed Oct 1, 1923 Patented Apr. 15, W30

snrsur osries EEMEB Q1? SHIRE/AGO, ILLINOIS, AQEIGNUB "1'0 THE PATENT AND LICENSING COBPQMTIGN, F BKiMLDN, MASSAGHE'SETTS, A GDBP@BA'JPION OF MASSA- G BQQFHIG ELEMENTS AND PBOD'UCT THEREOF Application med ooteber 1, "1933, eerie no. 885306. Eenewed December 234, 1927.

This invention relates to improvements in e processoimaking curved roofing elements end the product produced thereby and refers more articularly to the production of a roof- & ing e ement or structure eomprisin convex and concave cylindrical segments wlieh may be laid in a manner overla ping so es to simulate the well known Spanish tile or other tile-like ornamental roof structures Some W oi the subject matter of this ap lieation is disclosed genericelly in atent No. l tlilfll'ti, granted to me December 28,, Suchsubjeet matter which is eneric to both thesaid patent and this app cation die eleimed in this up. lication. V

Heretofore rooiing elements heve been mode of paper or rag felt saturated with esphelt, coated and carrying en [ornamental Writ surfacing. These elements have tehen 29 the form of shingles or similar flat structures and present, when placed on the root, a. flat monotonous, and to some, en inartistic, eppeerance.

Among the objects of the present invention Q are to produces roofin eiement devoid of this flat appearance on homing broken contours such esmey be obtainedztrom curved stincturee andcurved surteces, both of see were and concave form ever-leppin to pro duee a covering, among others, ei'mi or to that Y which results 1n placin eley tile and having the shadow linesin reef caused by streeturee having raised contours; to produce e roofin element which, when laid, gives the roof t e ezdect ppinted out yet possesses properties of lig 'tness which does not requite the heavy supporting structure "which is necessary for the plewinent of a clay tile roof; to produce a structure which, wh le having the shape and other eherecteristies of clay tile, toughnew and filesossesses ibilit so that reekage in treneportetion end hend 'ng is small; to provide it tile likeroeztting element whidh is more or -tees flexible so that it may eccommodete itself to expansion end contraction and the sheet oi the elements; .to rovide a. roofing element of fiber stock in which the curvature is inherent in the formation of the stools; to roduw e eurved roofingelement in'eontr tinctien papers,

After t e fibrous stock has been prepared to a. flat one in which there will be no tendency for such element tofletten out due to internal fiber stress; and to produce a roofing element which is waterproof, weatherproof and of substantial thickness and strength.

In the drawings: I

Fig. 1 is a perspective view of my improved roofing element. c

Fig. 2 is a pers active view of the cylindricel fibrous menu er from which the roofing element shown in Fig. 1 is cut.

Fig. 3 is a cross sectionel View taken on the lines 3-3 of Fig. 1.

Fi 4 is o. perspective View of the es semb ed elements-placed on a roof overlapping relation. a

Fig. 5 is across section of the root as laid, talren on the lines 5-5 of Fig. 4:.

Referring to the manner of making my improved product-I may first make an aqueousemulsion out esphelt "with colloidal clay and water, or with similar colloidal agent, capable of plroducing a ncnedhesiveiemelsion. The me ed of roducin this emulsion is set forth in issued nited tetes Letters Patent No. 1,302,810, detod May 6, 1919 in patent issued to me. The emulsion may be made in batch or may be made by a continuous process. The asphalt or bituminous material $0 used in the emulsion should prefereblybe of relatively high'melting oint so that it may possess a maximum stability under the heat of the summer sun. I have iound oxidized asphelts to be very setisfactory' for this as per ose.

i *1 e paper stock which comprises the fibrous constituent of my roofing element, me be mixed papers, news, ra e, limit, in feet a most any pa 1- is suitable dor this pur' ose ex-- on it is desired to provi e maxiand'stitfness it is wellto incorporate with such cheaper fibers as mixed a substantial amount of kraft which 18 well hydrated so as to produce a slowstock 5 capable of impertin at stiffness and stabilit to the his o roofing element.

111 the-heaters in the usual way, there is added either to the hmters or the stuff chest, e. pre- 1 cept that w mum strength formation of the next fibrous tube.

'tening out.

determined quantity of the asphalt emulsion prepared as above stated. Sufiicient emulsion is added so that the resulting stock when formed and dried is thoroughly impregnated with asphalt and is waterproof and weather resistant. Ordinarily 100 to 120 parts of asphalt, in emulsion form, to 100 parts of paper stock will be suflicient for this purpose. After the addition of the asphalt emulsion to the pa er stock, a small amount of alum or other occulating agent is added to the mixture in order to precipitate the dispersed particles of asphalt upon the fibrous stock.

The stock so prepared is fed to the well known wet machine, a brief 'descri tion of which it is thought will suflice as it orms no part of the present invention. This wet machine is an ordinary wet machine which is used to make u heavy boards and differs only in being provi ed with a rotatable reel carrying aplurality of small make up cores or reels which may be successfully contacted with the wet sheet and upon which the web is picked up and formed into a cylindrical tube. When a tube of the desired thickness is formed, a reel is drawn or moved out of contact wlth the blanket, bringing the consecutive make up core into contact for time T e make-u cores, with their fibrous tubes, are moved rom the reel, inserted in the press to remove further quantities of water and then collapsed so that the fibrous tube'with its contained asphalt may be removed therefrom.

It will be seen by this method of forming the fibrous. tube from a wet web, that the fibers contained in the tube have thus accommodated themselves to a position of curvature, tending to retain the curved structure and presenting a maximum resistance to fiattening out, thus distinguishing from laminated tubes or structures formed from flat sheets. In forming a tube by laminating pre-. viously prepared paper, the tendency, is to elongate the fibers on the outer or convex surface while compressing the fibers on the inner or concave surface of the sheet, thus introducing stress which tends to, relieve itself by resuming a fla position, in other words, fiathe method described of forming the tube from the wet web eliminates this tendency and eliminates the use of cementing mediums which are required in the laminat ing process just referred to.

The tubes thus formed are placed in a drying oven and 'subjected to a temperature of from 200 to 260 degs. F., the temperature being regulated so as to remove the water and cause the bitumen to coalesce and thoroughly impregnate the tube structure. This tube may be from 5" to 8" in diameter more or less; from to A" thick; and of any conenient length.

After the tube is dried, it is then cut into longitudinal sectors representing say, one

a cylindrical segment cut in the manner just described from the cylindrical core or tube 2, this tube 2 having been previously formed in the manner above described. The cylindrical segments may now be placed upon a conveyor and passed through a bath of hot asphalt, the purpose of which is to coat both surfaces and all edges of the roofing element; preferably this asphalt will be oxidized petroleum residuum of approximately 200 to 240 degs. melting point and may be 25 penetration. As the roofing elements emerge from their bath of asphalt, there may be projected on the hot coating, grit particles of predetermined color. In some instances, these grit articles may be projected on the convex sur ace of the roofing element while in others the concave surface will receive the projected grit.

As will be seen in Fig. 3, the finished product will comprise a fibrous base 3 coated on either or both sides with the bituminous waterproof coating 4 and surfaced with the colored grit surfacin 5.

Instead of using oxidized asphalt as a coating, there may be employed colorable pitches such as stearine pitches and the like in which pigments are incorporated so as to impart a predetermined shade to the bituminous coating material. In such instances, it Wlll be unnecessary to providea grit surface as the ornamental effect will be included in the bituminous covering.

I claim as my invention:

1. A process of producing roofing elements having curved surfaces comprising sheeting a fibrous stock into a Wet web, forming said sheeted fibrous stock into a tube from the wet web, drying the tube and slitting the same longitudinally and transversely into roofing elements of predetermined size and configuration.

2. A process of producing roofing elements having curved surfaces comprising sheeting a fibrous stock into a Wet web, forming said sheeted fibrous stock into a cylindrical tube from the wet web, drying the tube and slitting same longitudinally and transversely into roofing elements of predetermined size and configuration.

3. A process of producing roofing elements having curved surfaces comprising sheeting a fibrous stock carrying a waterproofing medium into a'wet web, forming said sheeted fibrous stock into a tube from the wet web, drying the tube, thereby causing the waterproofing medium to coalesce, and slitting same longitudinally and transversely into roofing elements of predetermined size and configuration.

4. A process of producingroofing elements having curved surfaces comprising sheeting a fibrous stock into a wet web, forming said sheeted fibrous stock into a tube from the wet web, drying and waterproofing the tube, and slitting same longitudinally and transversely into roofing elements.

5. A process of producing roofing elements having curved surfaces comprising sheeting a fibrous stock into a wet web, forming said sheeted fibrous stock into a tube from the wet web, drying the tube and slitting the same longitudinally and transversely into roofing elements,'and coating said elements.

6. A process of producing roofing elements having curved surfaces comprising sheeting a fibrous stock into a wet web, forming said sheeted fibrous stock into a tube from the wet web, drying the tube and slitting the same longitudinally and transversely into roofing elements, coating said elements and imbedding therein a grit surfacing.

7. A process of producing roofing elements having curved surfaces comprising sheeting a fibrous stock into a wet web, forming said sheeted fibrous stock into a tube from the wet web, drying the tube and slitting the same longitudinally into roofing elements of predetermined size and configuration.

8. A process of producing roofing elements having curved surfaces comprising sheeting a fibrous stock into a wet web, forming said sheeted fibrous stock into a cylindrical tube from the Wet web, drying the tube and slitting same longitudinally into roofing elements of predetermined size and configuration.

9. A process of producing roofing elements having curved surfaces comprising sheeting a fibrous stock carrying a waterproofing medium into a wet web, forming said sheeted fibrous stock into a tube from the wet web, drying the tube, thereby causing the waterproofing medium to coalesce, and slitting same longitudinally into roofing elements of predetermined size and configuration.

10. A process of producing roofing elements having curved surfaces comprising sheeting a fibrous stockinto a wet web, form'- ing said sheeted fibrous stock into a tube from the wet web, drying and waterproofing the tube, and slitting same longitudinally into roofing elements.

11. A process of producing roofing elements having curved surfaces comprising sheeting a fibrous stock into a wet web, forming said sheeted fibrous stock into a tube from the wet web, dr ing the tube and slitting the same longitu inally into roofing elements, and coating said elements.

12. A process of producing roofing elements having curved surfaces comprising sheetin a fibrous stock into a wet web, forming sai sheeted fibrous stock into a tube from the'wet web, drying the tube and slitting the same longitudinally into roofing elements, coating said elements and imbedding therein a grit surfacing.

13. Curved roofing elements cut on a longitudinal line of severance from a tube, comprising a fibrous base impregnated with waterproofing medium and devoid of internal fibrous stress.

14. A curved roofing element comprising a non-rigid fibrous base impregnated with a bituminous waterproofing medium, the fibres being disposed to eliminate internal strain, possessing the characteristics of having been formedin curved relation while wet.

15. Curved roofing elements produced by severing a tube longitudinally, comprising a fibrous base, the fibres being disposed to eliminate internal strain, and coated with a waterproof coating and an ornamental surfacing.

16. A process of producing roofing elements having curved surfaces comprising forming wet fibrous stock into a tube, drying, said tube and slitting same into roofing elements of predetermined size and configuration. r

17 A process of producing roofing ele ments having curved surfaces comprising forming wet fibrous stock containing Water repellent material, into a tube, drying said tube and slitting same into curved roofing elements devoid of internal fibrous strainand of pre-determin'ed size andv configuration.

18. 7A proces of producing roofing elements having curved surfaces comprising forming wet fibrous stock into a tube, drying said tube and slitting same into roofing elements of predetermined size and configuration, and coating the surfaces and all edges of said roofing element with waterproof material.

19. A process of producing roofing elements having curved surfaces comprising forming wet fibrous stock containing water repellent material into a tube, dryingsaidtube and slittin same into curved roofing elementsdevo1d of. internal fibrous strain and of pre-determined size and configuration, and coating surfaces and edges of said roofing element with waterproofing material.

20. A process of producing roofing elements havin curved surfaces, comprising forming wet fibrous stock into a tube, drying said tube and slitting same into roofing elements of predetermined size and configuration, and coating the surfaces and all edges of said roofing element with waterproof material and imbedding in said waterproof material, particles of granular surfacing.

21. A process of producing roofing elements having curved surfaces, comprising forming wet fibrous stock containing water repellent material into a tube, drying said tube and slittin same into curved roofing elements devoid 0 internal fibrous strain and of pre-determined size and configuration, and coating surfaces and ed es of said roofin element with Water-proo ng material, an imbedding in said water roofing material, particles of granular sur acing.

22. A curved roofing element comprising a flexible fibrous base impregnated with a bituminous Water-proofing material and devoidof internal fibrous stress.

23. A curved roofing element'comprising a flexible fibrous base impregnated with a bituminous water-proofing material and devoid of internal fibrous stress, having a bituminous coating of water-proofing material covering said element. v

24. The process of making roofing elements which comprises the steps of cutting the elements of suitable size and configuration from fibrous stock saturated with bituminous waterproofing material and in thereafter subjecting the saturated roofing elements to an application of bituminous coating material whereby to coat the exposed surface and seal the exposed edge of the saturated elements and in finally applying comminuted surfacing material to the thus coated elements.

LESTER KIRSCHBRAUN. 

